Capri L4-1597cc 1.6L DOHC (1992)
Differential: Service and Repair
DISASSEMBLE
1. On Capri models, measure and record the backlash of the pinion gears before disassembling the differential as follows:
a. Install both driveshafts on differential assembly.
b. Support driveshafts on V-blocks, then measure backlash of both pinion gears. Correct measurement is 0.000-0.004 inch.
c. Remove eight bolts securing ring gear to gear case.
d. Tap ring gear around its circumference with soft mallet to loosen, then remove ring gear from gear case.
2. On all models, mount gear case in vise equipped with soft jaws. Do not exert excess pressure on vise.
3. Remove pinion shaft roll pin using 4 mm diameter rod, at least 3 inches long, and hammer. Drive roll pin free of gear case.
4. Press front differential bearing from gear case using bearing puller attachment tool No. D84L-1123-A and step plate adapter tool No. D80L-630-3,
or equivalents.
5. On non-turbo models, remove speedometer drive gear from gear case.
6. On all models, remove rear differential bearing from gear case using puller tool No. T77F-4220-B and step plate adapter tool No. D80L-630-3, or
equivalents.
7. On turbo models, perform the following:
Pinion Gear And Thrust Washer Removal
a. Slide pinion shaft out of gear case, then remove pinion gears and thrust washers by rotating them out of gear case. Keep pinion and side gear
thrust washers with their respective gears for reinstallation.
b. Remove side gears, thrust washers, and speedometer from gear case.
ASSEMBLE
NOTE: Before assembly, wash all parts and dry with compressed air. Apply Mercon transaxle fluid to all surfaces following assembly.
1. Install speedometer drive gear to gear case, aligning locating tang on gear with groove in case.
2. Install new front differential bearing to gear case with a press and driver handle tool No. T80T-4OOO-W and bearing cone replacement tool No.
T87C-77000-C, or equivalents.
3. Install rear differential bearing to gear case with a press, using driver handle tool No. T80T-4000-W and bearing cone replacement tool No.
T87C-77000-C, or equivalents.
Side Gear Thrust Washer Thickness Selection Chart
4. On models equipped with turbo-charged engine, locate and record identification numbers on each side gear thrust washer. The Side Gear Thrust
Washer Thickness Selection Chart shows thickness of thrust washers. This information may be used when setting backlash of side and pinion
